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Battery box part 1

The bike needed a box to house the battery pack. Initially I was planning on doing something pretty rough with folded sheet metal at a local engineering shop, but my bud Jeremy offered to help, so we ended up designing and fabricating something much fancier with plywood. 
First I guesstimated the number of cells I could squeeze in the cavity between the seat tube and rear wheel with a few bits of board, and some old 18650 batteries I had lying around. I worked out I could fit 98 (14S7P).

I then came up with a more pleasing geometry with a trusty bit of cardboard, a ruler, and a protractor.


The outline was fed into Solidworks, and the files given to Jeremy. He then beautified the design, and did all the important Mechanical Engineering stuff like working out wall thicknesses, hole sizes, etc. A prototype laminate was cut out of acrylic, and we sanity checked the fit.


Prototype sidewall laminate
Jeremy then made a cardboard model of the battery box on Solidworks, and then we checked the…

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